A method of producing a vehicle includes determining the performance of aged adhesive coupons, which are subject to a worst-case scenario of manufacturing, aging, and stress testing. Virtual vehicle components are modeled using the performance of the aged adhesive coupons. The virtual vehicle components are then subjected to virtual mechanical forces to determine their virtual performance, which is then validated against the performance of identical real-life aged vehicle components subjected to identical mechanical forces. A virtual vehicle is modeled using the validated virtual vehicle components. The virtual performance of the virtual vehicle when subject to a virtual crash test is then compared against a predetermined standard, and the design of the virtual vehicle is considered feasible if its performance exceeds the predetermined standard. A vehicle is manufactured according to the feasible design of the virtual vehicle.
Legal claims defining the scope of protection. Each claim is shown in both the original legal language and a plain English translation.
1. A method of determining a feasibility of a vehicle design: providing an adhesive coupon including a first adhesive joint; aging the first adhesive joint; subjecting the aged first adhesive joint to a first mechanical force to determine a performance of the aged first adhesive joint; preparing a computer model of a first virtual vehicle according to the vehicle design, the first virtual vehicle including a first virtual adhesive joint having properties of the first adhesive joint before aging; subjecting the first virtual vehicle to a first simulated crash to determine a performance of the first virtual vehicle; subjecting a vehicle having the vehicle design to a crash having properties of the first simulated crash to determine a performance of the vehicle, the vehicle including a second adhesive joint having the properties of the first adhesive joint before aging; validating the performance of the first virtual vehicle with the performance of the vehicle; preparing a computer model of a second virtual vehicle according to the vehicle design, the second virtual vehicle including a second virtual adhesive joint having properties of the first adhesive joint after aging; subjecting the second virtual vehicle to a second simulated crash to determine a performance of the second virtual vehicle; and determining the vehicle design is feasible if the performance of the second virtual vehicle exceeds a predetermined standard.
The method evaluates the feasibility of a vehicle design by assessing the performance of adhesive joints under aging and crash conditions. The process begins by testing an adhesive coupon with a first adhesive joint, aging it, and then applying a mechanical force to measure its performance. A computer model of a first virtual vehicle is created, incorporating a virtual adhesive joint with properties matching the unaged adhesive joint. The virtual vehicle undergoes a simulated crash to assess its performance. A physical vehicle with the same design, featuring an unaged adhesive joint, is then subjected to a real crash with conditions matching the simulation. The virtual and physical vehicle performances are compared to validate the simulation model. A second virtual vehicle model is then prepared, this time with a virtual adhesive joint reflecting the properties of the aged adhesive joint. This second virtual vehicle undergoes another simulated crash, and the design is deemed feasible if its performance meets or exceeds a predetermined safety standard. This approach ensures that the vehicle design accounts for adhesive joint degradation over time while maintaining structural integrity during crashes.
2. The method of claim 1 , wherein: the adhesive coupon includes a first metal part adhesively bonded at the first adhesive joint to a second metal part; and the adhesive coupon is provided by applying a lubricant to a surface of one or more of the first metal part and the second metal part, then applying an adhesive in an uncured state over the lubricant, and then curing the adhesive to form the first adhesive joint between the first metal part and the second metal part.
This invention relates to a method for creating an adhesive coupon used in testing or evaluating adhesive bonds between metal parts. The problem addressed is ensuring reliable and reproducible adhesive bonding for testing purposes, particularly when evaluating the strength and durability of adhesive joints in metal structures. The method involves preparing an adhesive coupon by bonding a first metal part to a second metal part using an adhesive. A lubricant is first applied to a surface of one or both metal parts to facilitate bonding. An uncured adhesive is then applied over the lubricant, and the adhesive is cured to form a strong adhesive joint between the two metal parts. This process ensures that the adhesive coupon accurately represents real-world bonding conditions, allowing for precise testing of adhesive performance under various loads and environmental conditions. The lubricant application step helps control adhesion properties, making the coupon suitable for standardized testing protocols. The resulting adhesive coupon can be used to evaluate bond strength, fatigue resistance, or other mechanical properties of the adhesive joint. This method is particularly useful in industries where metal-to-metal adhesive bonding is critical, such as aerospace, automotive, and construction.
3. The method of claim 2 , wherein after applying the adhesive over the lubricant and before curing the adhesive, the adhesive is exposed for more than 12 hours to an environment having a humidity level at or above 50% relative humidity and a temperature of 30-50° C.
This invention relates to a method for bonding components using an adhesive, particularly in environments with controlled humidity and temperature conditions. The method addresses challenges in adhesive bonding where premature curing or inadequate adhesion strength occurs due to improper environmental conditions during the bonding process. The invention ensures optimal adhesive performance by exposing the adhesive to a specific humidity and temperature range before curing. The method involves applying a lubricant to a surface, followed by applying an adhesive over the lubricant. Before curing the adhesive, the adhesive is exposed to an environment with a humidity level of at least 50% relative humidity and a temperature between 30°C and 50°C for more than 12 hours. This exposure period allows the adhesive to achieve the desired properties, such as proper curing and adhesion strength, before final bonding. The method may also include additional steps, such as applying a primer to the surface before the lubricant or curing the adhesive after exposure to the controlled environment. The controlled exposure ensures that the adhesive reaches an optimal state for bonding, improving the reliability and durability of the final assembly. This approach is particularly useful in manufacturing processes where consistent adhesive performance is critical.
4. The method of claim 2 , wherein: the adhesive is cured by heating the adhesive; the adhesive is not heated to a temperature greater than 0-5° C. above a minimum temperature necessary to cure the adhesive; and the adhesive is not heated for a time greater than 0-5 minutes longer than a minimum time necessary to cure the adhesive.
This invention relates to a method for curing an adhesive in a controlled manner to optimize energy efficiency and processing time. The problem addressed is the excessive energy consumption and prolonged curing times often associated with adhesive curing processes, which can lead to higher costs and reduced productivity. The method involves heating the adhesive to cure it, but with strict control over both temperature and duration. Specifically, the adhesive is heated only to a temperature that is no more than 0-5° C above the minimum temperature required to achieve full curing. Additionally, the heating time is limited to no more than 0-5 minutes longer than the minimum time necessary for complete curing. This precise control ensures that the adhesive is cured efficiently without unnecessary energy expenditure or extended processing time. The method is particularly useful in industrial applications where minimizing energy use and optimizing production cycles are critical. By adhering to these constraints, the invention provides a more sustainable and cost-effective approach to adhesive curing.
5. The method of claim 1 , wherein the first adhesive joint is aged for longer than a predetermined time threshold by heating the first adhesive joint above a predetermined temperature threshold, and by subjecting the first adhesive joint to a humidity above a predetermined humidity threshold.
This invention relates to a method for aging adhesive joints to simulate long-term environmental exposure. The process involves accelerating the aging of a first adhesive joint by simultaneously applying heat, humidity, and time to the joint. The joint is heated above a predetermined temperature threshold while being exposed to humidity levels above a predetermined humidity threshold for a duration exceeding a specified time threshold. This controlled aging process is used to evaluate the long-term performance of adhesive bonds under environmental stress conditions. The method ensures that the adhesive joint undergoes accelerated degradation, allowing for rapid assessment of its durability and reliability in real-world applications. The technique is particularly useful in industries where adhesive bonds are subjected to varying temperature and humidity conditions, such as aerospace, automotive, and construction. By subjecting the adhesive joint to these controlled conditions, the method provides a reliable way to predict how the joint will perform over extended periods, reducing the need for lengthy natural aging tests. The process can be applied to various adhesive types and joint configurations to ensure they meet performance standards before deployment.
6. The method of claim 5 , wherein: the predetermined time threshold is within a range of 100-1000 hours; the predetermined temperature threshold is within a range of 70-100° C.; and the predetermined humidity threshold is within a range of 80-100% relative humidity.
This invention relates to environmental monitoring and control systems, specifically for detecting and mitigating conditions that may lead to degradation or failure of electronic or other sensitive equipment. The system monitors environmental parameters such as temperature, humidity, and time to assess the risk of corrosion or other damage. If any of these parameters exceed predefined thresholds, the system triggers corrective actions to prevent or reduce harm. The method involves continuously measuring temperature, humidity, and elapsed time in the monitored environment. The temperature threshold is set between 70-100°C, the humidity threshold is set between 80-100% relative humidity, and the time threshold is set between 100-1000 hours. If any of these thresholds are exceeded, the system initiates protective measures, such as adjusting ventilation, activating dehumidifiers, or alerting operators. The thresholds are selected based on empirical data indicating the conditions under which corrosion or other damage becomes likely. This approach ensures that sensitive equipment operates within safe environmental limits, extending its lifespan and reducing maintenance costs. The system is particularly useful in industrial, data center, or laboratory settings where precise environmental control is critical. The predefined ranges for temperature, humidity, and time provide a balanced approach to balancing sensitivity and practicality in environmental monitoring.
7. The method of claim 5 , wherein the predetermined time threshold, the predetermined temperature threshold, and the predetermined humidity threshold are each determined as a function of expected most-extreme conditions of use of a production vehicle having the vehicle design.
This invention relates to environmental monitoring and control systems for production vehicles, specifically addressing the challenge of determining optimal thresholds for temperature, humidity, and time to ensure reliable operation under extreme conditions. The method involves calculating predetermined thresholds for these parameters based on the expected most-extreme conditions a vehicle may encounter during its operational lifecycle. These thresholds are derived from the vehicle's design specifications and anticipated usage scenarios, ensuring the system can detect and respond to environmental factors that could compromise performance or safety. The method integrates these thresholds into a monitoring system that continuously evaluates real-time environmental data against the predefined limits. If any parameter exceeds its threshold, the system triggers corrective actions, such as adjusting vehicle operations or alerting the driver. This approach ensures the vehicle operates within safe and efficient parameters, even under harsh conditions, by proactively mitigating risks associated with extreme temperature, humidity, or prolonged exposure to adverse environments. The invention enhances vehicle durability, reliability, and safety by tailoring environmental thresholds to the specific design and expected use cases of the vehicle.
8. The method of claim 7 , wherein the predetermined time threshold, the predetermined temperature threshold, and the predetermined humidity threshold are each determined using an Arrhenius equation.
This invention relates to a method for determining environmental thresholds for a process or system, particularly in applications where temperature, humidity, and time interact to affect material degradation or performance. The method addresses the challenge of accurately predicting environmental conditions that could lead to failures or performance degradation in materials or systems, such as electronics, pharmaceuticals, or industrial components. The method involves setting predetermined thresholds for time, temperature, and humidity, which are critical for assessing the stability or reliability of a material or system under specific environmental conditions. These thresholds are calculated using the Arrhenius equation, a well-known model in chemical kinetics that describes the relationship between reaction rates and temperature. By applying the Arrhenius equation, the method enables precise determination of how temperature and humidity over time influence degradation processes, allowing for more accurate predictions of material or system lifespan. The method may be used in quality control, reliability testing, or environmental monitoring, where understanding the interplay between temperature, humidity, and time is essential. For example, in semiconductor manufacturing, this method could help predict the shelf life of components under varying storage conditions. Similarly, in pharmaceuticals, it could ensure that drugs remain stable under different environmental exposures. The use of the Arrhenius equation ensures that the thresholds are scientifically grounded, providing reliable data for decision-making in industrial and scientific applications.
9. The method of claim 1 , wherein a temperature of the adhesive coupon is 70-100° C. when the aged first adhesive joint subjected to the first mechanical force.
This invention relates to a method for evaluating the durability of adhesive joints, particularly in high-temperature environments. The method addresses the challenge of assessing how adhesive bonds degrade over time under mechanical stress and elevated temperatures, which is critical for applications in aerospace, automotive, and construction industries where structural integrity is paramount. The method involves preparing an adhesive coupon, which is a test specimen of the adhesive material, and forming a first adhesive joint by bonding the coupon to a substrate. The joint is then aged under controlled conditions to simulate real-world degradation. After aging, the joint is subjected to a first mechanical force, such as tension, shear, or peel, while maintaining the adhesive coupon at a temperature between 70-100°C. This temperature range is selected to replicate operational conditions where adhesives may experience thermal cycling or sustained heat exposure. The response of the joint to the applied force is measured to determine its remaining strength and failure characteristics, providing insights into the adhesive's long-term performance. The method may also include additional steps, such as applying a second mechanical force to a second adhesive joint under different conditions to compare performance or analyzing the failure modes to identify weaknesses in the adhesive formulation or bonding process. The technique enables engineers to optimize adhesive materials and bonding procedures for reliability in high-temperature applications.
10. The method of claim 1 , further including: preparing a computer model of a virtual vehicle component including a third virtual adhesive joint having properties of the aged first adhesive joint; subjecting the virtual vehicle component to a simulated mechanical force to determine a performance of the virtual vehicle component; subjecting a vehicle component to second mechanical force having properties of the simulated mechanical force to determine a performance of the vehicle component, the vehicle component including a third adhesive joint having properties of the aged first adhesive joint; and validating the performance of the virtual vehicle component with the performance of the vehicle component; wherein the second virtual vehicle includes the virtual vehicle component.
This invention relates to validating the performance of vehicle components with adhesive joints, particularly when those joints have aged. The problem addressed is ensuring that real-world performance of vehicle components with aged adhesive joints matches predicted performance from computer simulations. The method involves creating a computer model of a virtual vehicle component that includes a virtual adhesive joint with properties matching an aged adhesive joint. This virtual component is then subjected to simulated mechanical forces to assess its performance. In parallel, a physical vehicle component with an adhesive joint that also matches the aged properties is tested under real-world mechanical forces that replicate the simulated conditions. The results from both the virtual and physical tests are compared to validate the accuracy of the simulation model. This approach ensures that the virtual model reliably predicts the behavior of real-world components, even as adhesive joints degrade over time. The method is particularly useful for automotive engineering, where component durability and safety are critical. By validating simulations against physical tests, manufacturers can reduce development costs and improve reliability.
11. The method of claim 10 , wherein a temperature of the vehicle component is 70-100° C. when the vehicle component is subjected to the second mechanical force.
This invention relates to a method for processing a vehicle component, specifically addressing the challenge of optimizing mechanical force application during manufacturing or assembly to improve material properties or structural integrity. The method involves applying a first mechanical force to the vehicle component, followed by a second mechanical force under controlled conditions. The second mechanical force is applied when the vehicle component is at an elevated temperature, specifically between 70-100° C. This temperature range is critical for enhancing the component's response to the mechanical force, potentially improving deformation behavior, stress distribution, or material bonding. The method may be used in automotive manufacturing, particularly for components requiring precise shaping or joining processes, such as metal forming, welding, or assembly operations. The controlled application of mechanical forces at elevated temperatures ensures consistent quality and performance of the vehicle component. The invention may also include pre-treatment steps, such as heating or surface preparation, to ensure optimal conditions for the mechanical force application. The method is designed to be adaptable to various vehicle components, including body panels, structural frames, or engine parts, where mechanical and thermal processing is essential for achieving desired mechanical properties.
12. A method of producing a vehicle comprising: preparing an adhesive coupon including a first adhesive joint; aging the first adhesive joint; determining a performance of the aged first adhesive joint when subjected to a first mechanical force; preparing a first virtual vehicle having a vehicle design, and including a first virtual adhesive joint having properties of the first adhesive joint before aging; determining a performance of the first virtual vehicle when subjected to a first simulated crash; subjecting a test vehicle having the vehicle design to a crash having properties of the first simulated crash to determine a performance of the test vehicle, the test vehicle including a second adhesive joint having the properties of the first adhesive joint before aging; validating the performance of the first virtual vehicle with the performance of the test vehicle; preparing a computer model of a second virtual vehicle according to the vehicle design, the second virtual vehicle including a second virtual adhesive joint having properties of the first adhesive joint after aging; subjecting the second virtual vehicle to a second simulated crash to determine a performance of the second virtual vehicle; and if the performance of the second virtual vehicle exceeds a predetermined standard, then producing the vehicle according to the vehicle design, the vehicle including a third adhesive joint having properties of the first adhesive joint.
The invention relates to a method for producing a vehicle with optimized adhesive joint performance under crash conditions. The method addresses the challenge of ensuring that adhesive bonds in vehicles maintain structural integrity during collisions, particularly as adhesives age over time. The process begins by preparing an adhesive coupon with a first adhesive joint, which is then aged to simulate real-world conditions. The performance of this aged joint is tested under a mechanical force to assess its strength. A first virtual vehicle model is created with a virtual adhesive joint that mimics the properties of the unaged adhesive. This virtual vehicle undergoes a simulated crash to evaluate its performance. A physical test vehicle, also incorporating an unaged adhesive joint matching the virtual model, is subjected to an actual crash test under conditions matching the simulation. The results from the virtual and physical tests are compared to validate the accuracy of the virtual model. A second virtual vehicle model is then generated, this time with a virtual adhesive joint that reflects the properties of the aged adhesive. This model undergoes a second simulated crash to determine its performance. If the results meet predetermined safety standards, the vehicle is produced with an adhesive joint that matches the aged properties from the initial coupon. This method ensures that the vehicle's adhesive joints will perform reliably in real-world crash scenarios, accounting for aging effects.
13. The method of claim 12 , wherein: the adhesive coupon includes a first metal part adhesively bonded at the first adhesive joint to a second metal part; and the adhesive coupon is provided by applying a lubricant to a surface of one or more of the first metal part and the second metal part, then applying an adhesive in an uncured state over the lubricant, then exposing the adhesive for 12-36 hours to an environment having a humidity level at or above 50% relative humidity and a temperature of 30-50° C., and then curing the adhesive to form the first adhesive joint between the first metal part and the second metal part.
This invention relates to the field of adhesive bonding for metal parts, specifically addressing challenges in achieving strong, durable bonds in high-performance applications. The method involves creating an adhesive coupon by bonding a first metal part to a second metal part using a controlled adhesive curing process. The process begins by applying a lubricant to the surface of one or both metal parts to facilitate handling and bonding. An uncured adhesive is then applied over the lubricated surface. The adhesive is exposed to an environment with 50% or higher relative humidity and a temperature between 30-50°C for 12-36 hours to condition the adhesive before curing. This conditioning step enhances the adhesive's bonding properties. After conditioning, the adhesive is cured to form a strong adhesive joint between the two metal parts. This method ensures optimal adhesion by controlling environmental factors during the curing process, improving bond strength and reliability in metal-to-metal bonding applications. The technique is particularly useful in industries requiring high-performance adhesive joints, such as aerospace, automotive, and construction.
14. The method of claim 13 , wherein: the adhesive is cured by heating; and the adhesive is not heated to a temperature greater than 0-5° C. above a minimum temperature necessary to cure the adhesive; and the adhesive is not heated for a time greater than 0-5 minutes longer than a minimum time necessary to cure the adhesive.
This invention relates to a method for curing an adhesive in a bonding process, specifically addressing the problem of excessive energy consumption and potential material degradation caused by overheating or prolonged heating during adhesive curing. The method involves heating the adhesive to cure it, but with precise control to avoid unnecessary energy use and thermal damage. The adhesive is heated only to a temperature that is no more than 5°C above the minimum required for curing, ensuring efficient energy use without overheating. Additionally, the heating duration is limited to no more than 5 minutes longer than the minimum time needed for curing, preventing excessive exposure to heat. This controlled curing process helps maintain the integrity of the adhesive and the bonded materials while optimizing energy efficiency. The method is particularly useful in applications where precise temperature and time control are critical, such as in manufacturing processes involving heat-sensitive materials or where energy efficiency is a priority. By minimizing both the temperature and duration of heating, the method reduces the risk of thermal degradation and ensures consistent bonding quality.
15. The method of claim 12 , wherein the first adhesive joint is aged for a time of 100-1000 hours by heating the first adhesive joint to a temperature of 70-100° C. and subjecting the first adhesive joint to a relative humidity of 80-100%.
This invention relates to a method for aging adhesive joints to evaluate their durability under accelerated environmental conditions. The method involves subjecting a first adhesive joint to controlled heating and humidity to simulate long-term degradation. The joint is heated to a temperature between 70-100°C while being exposed to a relative humidity of 80-100% for a duration of 100-1000 hours. This process accelerates the aging of the adhesive, allowing for rapid assessment of its performance under stress. The method may be used to test the bond strength, adhesion, and resistance to environmental factors such as moisture and temperature fluctuations. The technique is particularly useful in industries where adhesive joints are critical, such as aerospace, automotive, and construction, where long-term reliability is essential. By simulating extended exposure to harsh conditions, the method helps identify potential failures early in the development process, ensuring that only durable adhesives are used in final applications. The controlled aging process provides a standardized way to compare different adhesive formulations and optimize their performance for specific environmental challenges.
16. The method of claim 15 , wherein: the time is determined as a function of an expected duration of use of the vehicle; the temperature is determined as a function of an expected most-extreme temperature exposure of the vehicle during the duration of use of the vehicle; and the relative humidity is determined as a function of an expected most-extreme relative humidity exposure of the vehicle during the duration of use of the vehicle.
This invention relates to optimizing the testing of a vehicle's battery system by simulating real-world environmental conditions. The problem addressed is ensuring battery reliability under varying operational conditions without excessive or unnecessary testing. The method involves determining key environmental parameters—time, temperature, and relative humidity—to create a controlled test environment that accurately reflects the vehicle's expected usage. The time parameter is calculated based on the expected duration of the vehicle's use, ensuring the test duration matches real-world operational periods. The temperature is set according to the most extreme temperature the vehicle is likely to encounter during its use, simulating worst-case thermal conditions. Similarly, the relative humidity is determined by the highest expected humidity level the vehicle will face, replicating the most challenging moisture exposure scenarios. By adjusting these parameters, the method ensures the battery system is tested under conditions that closely mimic real-world extremes, improving reliability assessments while minimizing unnecessary testing. This approach optimizes testing efficiency and accuracy, reducing costs and time while ensuring robust performance validation.
17. The method of claim 12 , wherein the first adhesive joint includes a butt joint, a scarf joint; a lap joint, a strap joint, a T-joint, a corner joint, an edge joint, a flange joint, a flange V-groove joint, or combinations thereof.
This invention relates to methods for forming adhesive joints in composite structures, particularly for aerospace applications where strength, durability, and precision are critical. The method addresses challenges in bonding composite materials, such as ensuring proper alignment, minimizing stress concentrations, and achieving consistent bond strength across different joint configurations. The invention focuses on optimizing the adhesive joint design to enhance structural integrity and performance. The method involves forming a first adhesive joint between composite components using one or more joint configurations, including butt joints, scarf joints, lap joints, strap joints, T-joints, corner joints, edge joints, flange joints, flange V-groove joints, or combinations thereof. Each joint type is selected based on the specific structural requirements, load-bearing needs, and environmental conditions of the application. The adhesive joint is formed by applying an adhesive material to the mating surfaces of the composite components and curing the adhesive under controlled conditions to ensure a strong, durable bond. The method may also include surface preparation steps, such as cleaning, roughening, or applying primers, to improve adhesion. The resulting joint provides high strength, resistance to fatigue, and reliability in demanding environments, such as those encountered in aerospace and automotive industries.
18. The method of claim 12 , wherein the first mechanical force includes a fracture energy test, a KS-2 test, a tensile test, a peel test including a coach peel test or a T-peel test, a cantilever beam test, a double cantilever beam test including a tapered double cantilever beam test and a rigid double cantilever beam test, a shear test including a lap shear test including a thick-adherend lap shear test, a torsion test, an impact test, a torque test, a pin-and-collar test, a bulk tension test, a bulk shear test, a cleavage test including wedge impact peels, or combinations thereof.
This invention relates to methods for evaluating mechanical properties of materials, particularly adhesive or bonded structures, by applying specific mechanical forces to assess performance. The method involves subjecting a material or bonded assembly to various standardized mechanical tests to determine its strength, durability, and failure characteristics. These tests include fracture energy testing, KS-2 testing, tensile testing, peel testing (such as coach peel or T-peel), cantilever beam testing, double cantilever beam testing (including tapered and rigid variants), shear testing (such as lap shear or thick-adherend lap shear), torsion testing, impact testing, torque testing, pin-and-collar testing, bulk tension testing, bulk shear testing, and cleavage testing (including wedge impact peels). The method may also combine multiple tests to provide a comprehensive evaluation of the material's mechanical behavior under different loading conditions. This approach helps identify weaknesses, optimize material selection, and ensure reliability in applications where mechanical integrity is critical.
19. The method of claim 12 , wherein: a temperature of the adhesive coupon is 70-100° C. when the performance of the adhesive coupon is determined; and a temperature of the vehicle component is 70-100° C. when the performance of the vehicle component is determined.
This invention relates to evaluating the performance of adhesive coupons and vehicle components in automotive applications, particularly under elevated temperature conditions. The method involves testing adhesive coupons and vehicle components to assess their performance, with specific temperature constraints applied during testing. The adhesive coupon and the vehicle component are each maintained at a temperature between 70°C and 100°C during performance evaluation. This ensures that the testing conditions simulate real-world operating environments where adhesives and vehicle components may experience high temperatures, such as in engine compartments or near exhaust systems. By controlling the temperature within this range, the method provides accurate and reliable performance data, helping to identify suitable materials for automotive applications where thermal stability is critical. The approach ensures that adhesives and components maintain their structural integrity and bonding strength under elevated temperature conditions, which is essential for vehicle safety and durability. The method may be used in quality control, material selection, or research and development for automotive adhesives and components.
20. The method of claim 12 , further including: preparing a computer model of a virtual vehicle component including a third virtual adhesive joint having properties of the aged first adhesive joint; subjecting the virtual vehicle component to a simulated mechanical force to determine a performance of the virtual vehicle component; subjecting a vehicle component to second mechanical force having properties of the simulated mechanical force to determine a performance of the vehicle component, the vehicle component including a fourth adhesive joint having properties of the aged first adhesive joint; and validating the performance of the virtual vehicle component with the performance of the vehicle component; wherein the second virtual vehicle includes the virtual vehicle component; and wherein a temperature of the vehicle component is 70-100° C. when the vehicle component is subjected to the second mechanical force.
This invention relates to a method for validating the performance of vehicle components with adhesive joints, particularly focusing on aging effects. The method addresses the challenge of accurately assessing how adhesive joints degrade over time and under thermal conditions, ensuring real-world reliability. The process begins by creating a computer model of a virtual vehicle component with a virtual adhesive joint that mimics the properties of an aged adhesive joint. This model is then subjected to a simulated mechanical force to evaluate its performance. Subsequently, a physical vehicle component with an adhesive joint matching the aged properties is tested under a mechanical force that replicates the simulated conditions. The performance of both the virtual and physical components is compared to validate the accuracy of the computer model. A key aspect is the testing environment, where the physical component is exposed to temperatures between 70-100°C during mechanical testing, simulating real-world thermal stresses. This ensures the validation process accounts for both mechanical and thermal aging effects on adhesive joints. The method integrates computational modeling with physical testing to improve the reliability of vehicle components with adhesive joints, particularly under elevated temperature conditions.
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February 8, 2019
March 1, 2022
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